The Double Headed Polished Round Cornered Pure Tungsten Electrode is used for projection welding positions where the electrode face must remain firm, smooth, and dimensionally stable under repeated pressure. It is made from pure tungsten material with a tungsten content of ≥99.5%, giving the electrode strong resistance to high-temperature softening, surface indentation, and edge damage.
The product adopts a double-headed symmetrical structure. Both ends are finely polished and can be used as working contact faces. The rounded-corner design helps reduce sharp-edge stress during pressing, making the electrode suitable for projection welding of nuts, fasteners, terminals, precision stamped parts, and other components that require concentrated welding pressure.
Technical Parameters
Item | Specification |
Material | Pure Tungsten (≥ 99.5%) |
Shape | Double-headed symmetrical |
Dimensions | 43 × 20 × 8 mm (L × W × T) |
Tolerance | As per customer drawings or national standards |
Manufacturing Process | Precision machining and fine polishing |
Surface Finish | Polished surface with low roughness |
Corner Design | Rounded corners (custom radius available) |
Application Method | Projection welding |
Heat Resistance | Excellent under high-current welding |
Customization | Available upon request (shape, size, tolerance, etc.) |
All parameters are customizable according to customer requirements, including purity level, geometry, tolerance, and surface treatment.
Product Features
Pure tungsten is selected for this electrode because projection welding often generates concentrated heat in a small contact area. Compared with softer conductive materials, tungsten provides higher hardness and better resistance to pressure deformation.
The ≥99.5% tungsten material helps the working face keep its shape during repeated welding cycles. This is useful when the weld point requires stable pressing force and a contact surface that does not collapse easily.
Both working ends are polished to create a smoother contact surface. The polished finish helps reduce unstable contact caused by rough machining marks and supports cleaner pressure transfer between the electrode and the workpiece.
For precision projection welding, surface condition directly affects contact resistance, heat concentration, and weld repeatability. A fine polished surface helps the electrode perform more consistently in repeated production.
The rounded corners reduce the risk of edge chipping and stress concentration when the electrode is pressed against the workpiece. This design is especially useful for high-pressure welding fixtures where sharp edges may become damaged after repeated use.
The corner radius can be adjusted according to the workpiece shape, fixture pressure, and required contact area. A suitable radius helps improve service stability without affecting the effective working face.
The electrode is processed by precision machining to ensure correct size, flatness, and symmetrical geometry. Accurate dimensions help the part fit the welding holder properly and reduce installation deviation.
Stable machining quality is important for double-headed electrodes because both ends need to meet working requirements. Proper dimensional control ensures that the electrode can be reversed and reused when one side reaches its wear limit.
EAA can produce pure tungsten electrodes according to customer drawings or samples. Custom options include length, width, thickness, corner radius, surface finish, flatness, tolerance, and special mounting structures.
This customization is suitable for customers using non-standard welding fixtures, special projection welding positions, or components with limited contact space.
Applications
This product is mainly used in projection welding applications that require a hard, heat-resistant, and stable electrode contact surface. Typical uses include:
Nut projection welding on metal plates
Stud and fastener welding
Electrical terminal welding
Precision stamped component welding
Automotive small-part welding
Hardware components with raised welding points
Welding fixtures requiring a reversible double-ended electrode
Production conditions where standard copper electrodes wear or deform too quickly
The electrode is especially suitable for welding positions where the contact area is small, pressure is concentrated, and the working face must maintain its shape for consistent weld quality.
Projection Welding Process
Projection welding concentrates welding heat at raised points, embossments, or designed contact areas on the workpiece. During the process, the electrode applies pressure while current passes through the projection area. The projection collapses under heat and pressure, forming the welded joint.
In this process, the electrode does not need a sharp tip. Instead, it needs a stable and durable contact face. The polished pure tungsten surface helps maintain pressure consistency, while the rounded edge reduces the chance of damage during repeated pressing.
Concentrates welding heat at the designed projection point
Helps reduce unnecessary heating of surrounding material
Suitable for welding nuts, studs, fasteners, and small metal components
Supports accurate positioning through workpiece projection design
Allows multiple weld points to be formed in one operation when the fixture is properly designed
Works well in automated production where repeatability is required
For this type of welding, the electrode face condition is critical. A stable, hard, and polished tungsten surface helps control the pressure path and supports consistent joint formation.
Projection welding electrodes must withstand repeated mechanical impact, concentrated current, and localized heat. If the electrode face becomes uneven, softened, or chipped, the weld quality may become unstable.
For this reason, the electrode should have high hardness, good heat resistance, accurate flatness, and a clean working surface. The double-headed polished pure tungsten structure is suitable for applications where the contact face must remain stable under demanding welding conditions.
Customization Services
EAA provides custom pure tungsten electrode manufacturing for different welding machines, fixtures, and production requirements. Customers can send drawings, samples, or application information for evaluation.
Customized production can be arranged for special dimensions, non-standard working faces, mounting grooves, positioning slots, stepped structures, and different polishing requirements.
The electrode can be manufactured in different lengths, widths, and thicknesses according to fixture requirements. Working face size, installation clearance, and usable height can also be adjusted.
For double-headed designs, both ends can be processed to the same specification or modified according to different welding contact requirements.
Besides the standard double-headed round-corner structure, the electrode can be made with flat ends, stepped sections, chamfered sides, grooves, holes, or special mounting profiles.
The shape design should match the welding holder, workpiece contact area, and required pressure direction. Proper structure design helps reduce adjustment time during installation.
Fine polishing can be applied to one or both working faces depending on the application. Surface roughness can be controlled according to welding cleanliness, contact stability, and appearance requirements.
For applications that require less marking on the workpiece surface, a smoother contact face is recommended.
EAA can assist with electrode material selection, corner radius design, working face size confirmation, and structure optimization based on the welding process.
To improve matching accuracy, customers are encouraged to provide workpiece material, projection shape, welding current range, welding pressure, fixture photos, or sample parts.
For standard or similar structures, sample production can be arranged efficiently after drawing confirmation. For customized tungsten electrodes, delivery time depends on material availability, machining complexity, polishing requirements, and order quantity.
EAA supports sample orders, small-batch trial production, and batch supply for long-term welding projects.
Sourcing critical industrial components requires a partner who understands the high stakes of uninterrupted production. We do not just supply parts; we deliver reliability, precision, and engineering excellence tailored to your specific fabrication requirements.
Uncompromising Quality Control: Every single electrode undergoes rigorous metallurgical and dimensional inspections before leaving our facility, ensuring zero defects and absolute readiness for your assembly line.
Rapid Scalability: Our advanced manufacturing infrastructure is designed to handle high-volume demands without sacrificing the microscopic precision required for flawless performance.
Direct Manufacturing Advantage: By eliminating intermediaries, we provide a streamlined procurement process, ensuring highly competitive pricing structures and direct access to the engineers who design your components.
Agile Production Turnaround: We recognize that downtime is incredibly costly. Our optimized supply chain and flexible order management systems guarantee on-time delivery, keeping your operations running smoothly.
End-to-End Engineering Support: From the initial blueprint analysis to post-installation troubleshooting, our technical specialists remain at your disposal to maximize the efficiency of your welding processes.
Frequently Asked Questions (FAQ)
1. Why choose pure tungsten electrodes for projection welding instead of copper-based electrodes?
Pure tungsten electrodes offer superior hardness and high-temperature resistance (melting point 3,410°C), lasting 5-10 times longer than copper electrodes while withstanding the extreme pressures of projection welding.
2. What is the expected service life of your tungsten electrodes?
Our electrodes typically perform 50,000-100,000+ welds before replacement, depending on welding parameters and materials.
3. Can you customize electrode dimensions for our specific application?
Yes, we fully customize all dimensions and specifications based on your technical drawings and welding requirements.
4. How do I maintain the tungsten electrodes?
Regularly clean electrode surfaces, control welding parameters within recommended ranges, and ensure adequate cooling for optimal performance.
5. What materials can be welded using pure tungsten electrodes?
Our electrodes are suitable for steel, stainless steel, aluminum alloys, copper, brass, galvanized materials, and various thicknesses from 0.5mm to 10mm+.
